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Production of ophthalmic devices based on photo-induced step growth polymerization

a technology of photo-induced step growth and ophthalmic devices, which is applied in the field of production of ophthalmic devices, can solve the problems of slow cure process, hinder the realization of all of the great potentials of such technology, and molds may undergo non-uniform shrinkage, and achieve the effect of low viscosity

Active Publication Date: 2011-08-23
ALCON INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a method for producing soft hydrogel contact lenses using a fluid composition that includes at least one prepolymer with multiple first propagating groups that can undergo photo-induced step-growth polymerization. The composition is introduced into a mold and then actinically irradiated or thermally curved to crosslink the prepolymer and form the contact lens. The resulting contact lens has a high water content and is comfortable to wear. The invention also provides a prepolymer suitable for making soft hydrogel contact lenses and a fluid composition for making medical devices, particularly soft hydrogel contact lenses.

Problems solved by technology

First, the curing process is fast, at a time scale of seconds.
Disposable plastic molds inherently have variations in the dimensions, because, during injection-molding of plastic molds, fluctuations in the dimensions of molds can occur as a result of fluctuations in the production process (temperatures, pressures, material properties), and also because the resultant molds may undergo non-uniformly shrinking after the injection molding.
However, there are some practical limitations which hinder realization of all of the great potentials of such technology.
Lenses made from crosslinking of a prepolymer with a low molecular mass may not have a desired mechanical strength, such as, for example, low tearing resistance.
Hydrogel contact lenses having low mechanical strength may not be suitable for daily- and extended-wear modality.

Method used

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  • Production of ophthalmic devices based on photo-induced step growth polymerization
  • Production of ophthalmic devices based on photo-induced step growth polymerization
  • Production of ophthalmic devices based on photo-induced step growth polymerization

Examples

Experimental program
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Effect test

example 1

Synthesis of Norbornene Carbonyl Chloride

[0178]A 500 mL sulfur flask was equipped with magnetic stirring, addition funnel, thermometer, reflux condenser with N2-inlet adapter, and outlet adapter connected to a trap immersed in a dry ice / acetone bath. 58.28 g of 2-norbornene-5-carboxylic acid (Aldrich) were charged to the reactor under a positive flow of nitrogen, then 31.4 mL of thionyl chloride (51.32 g). 450 mL of methyl-tert-butyl ether were added, an ice bath was applied, and the contents of the reactor were stirred to mix and cool to 3° C. 51.6 mL of triethylamine (37.45 g) and 20 mL of MTBE were charged to the addition funnel and added dropwise to keep temperature less than 10° C. On completion of the addition the ice bath was removed and the flask was stirred for one hour. The resulting suspension was filtered to remove triethylamine hydrochloride. The resulting clear yellow solution was reduced to an oil on a rotary evaporator and purified by fractional distillation at 8 mBa...

example 2

Synthesis of alpha-omega-diacrylamide Poly(dimethylsiloxane) 4500

[0179]In a 4-L beaker, 61.73 g of Na2CO3 (996 mEq), 80 g of NaCl and 1.52 kg of deionized water were mixed to dissolve. In a separate 4-L beaker, 700 g of alpha, omega-aminopropyl-polydimethylsiloaxane (Shin-Etsu manufacture, MW ca. 4500, 305 mEq) were dissolved in 1000 g of hexane. A 4-L reactor was equipped with overhead stirring with turbine agitator and a 250-mL addition funnel with micro-flow controller. The two solutions were then charged to the reactor, and mixed for 15 minutes with heavy agitation to produce an emulsion. 36.6 g of acryloyl chloride (405 mEq) was dissolved in 100 mL of hexane and charged to the addition funnel. The acryloyl chloride solution was added dropwise to the emulsion under heavy agitation over one hour. The emulsion was stirred for 30 minutes on completion of the addition and then agitation was stopped and the phases were allowed to separate overnight. The aqueous phase was decanted and...

example 3

Synthesis of alpha-omega-diacrylamide Poly(dimethylsiloxane) 2500

[0180]In a 4-L beaker, 111.1 g of Na2CO3 hydrate (1790 mEq), 80 g of NaCl and 1.52 kg of deionized water were mixed to dissolve. In a separate 4-L beaker, 700 g of alpha, omega-aminopropyl-polydimethylsiloaxane (Shin-Etsu manufacture, MW ca. 2500, 560 mEq) were dissolved in 1000 g of hexane. A 4-L reactor was equipped with overhead stirring with turbine agitator and a 250-mL addition funnel with micro-flow controller. The two solutions were then charged to the reactor, and mixed for 15 minutes with heavy agitation to produce an emulsion. 65.89 g of acryloyl chloride (728.1 mEq) was dissolved in 100 mL of hexane and charged to the addition funnel. The acryloyl chloride solution was added dropwise to the emulsion under heavy agitation over one hour. The emulsion was stirred for 30 minutes on completion of the addition and then agitation was stopped and the phases were allowed to separate overnight. The aqueous phase was ...

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Abstract

The invention provide a new lens curing method for making hydrogel contact lenses. The new lens curing method is based on actinically-induced step-growth polymerization. The invention also provides hydrogel contact lenses prepared from the method of the invention and fluid compositions for making hydrogel contact lenses based on the new lens curing method. In addition, the invention provide prepolymers capable of undergoing actinically-induced step-growth polymerization to form hydrogel contact lenses.

Description

[0001]This application claims the benefits under 35 USC 119(e) of the U.S. Provisional Patent Application No. 60 / 869,812 filed Dec. 13, 2006 herein incorporated by reference in its entirety.[0002]The present invention is related to a method for making ophthalmic devices, in particular hydrogel contact lenses. In particular, the present invention is related to a method for cast-molding of hydrogel contact lenses based on photo-induced step growth polymerization. In addition, the present invention is related to actinically crosslinkable prepolymers and compositions useful for making polymeric articles, preferably ophthalmic device, more preferably soft hydrogel contact lenses.BACKGROUND[0003]A great effort has been made to develop technologies for cast molding of hydrogel contact lenses with high precision, fidelity and reproducibility and at low cost. One of such manufacturing technologies is the so-called Lightstream Technology™ (CIBA Vision) involving a lens-forming composition bei...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): G02B1/04
CPCG02B1/043C08F275/00B29D11/00038C08L83/04C08L51/085G02B1/041C08L33/08C08L33/10C08L23/20
Inventor MEDINA, ARTURO NORBERTOSCOTT, ROBERTSMITH, DAWN ALISON
Owner ALCON INC
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